Pop-up package assembly for a flat product and method of packaging

ABSTRACT

Method and apparatus for packaging flat products such as a computer disk into a package assembly of sheet material wherein the sheet material folds closed into a two dimensional configuration having a thin lateral profile or folds open into a three dimensional self supporting display stand. The method of packaging comprises the steps of providing a single continuous web of sheet material having two horizontally oriented columns defining first and second major panels separated by a vertical slit line; forming sub-panels in the first major panel with the sub-panels separated by at least one centrally located vertically extending score or perforation line; forming sub-panels in the second major panel with a plurality of parallel spaced vertically extending score or perforation lines for separating each of the sub-panels in the second major panel; applying adhesive to each of the major panels to form linear parallel lines of adhesive on the first of major panel extending vertically down the first major panel and to form an array of adhesive lines on the second major panel at a location adjacent to the vertical slit line separating the first major panel from the second major panel; separating the first major panel from the second major panel along said vertical slit line; folding the second major panel over the first major panel such that at least the two outer sub-panel in the second major panel furthest from the slit line overlies said centrally located score or perforation line in said first major panel without causing any adherence between said outer sub-panels and the first major panel; folding over said two outer sub-panels over score or perforation lines to form a pocket or flap between an outer sub-panel and one of the other previously folded sub-panels for the placement of a flat product; folding the sub-panels of the first and second major panel into a folded over assembly forming a three dimensional configuration when folded open and forms a substantially two dimensional configuration when folded closed; and cutting the web transversely to form a plurality of package assemblies one for each flat product.

BACKGROUND OF THE INVENTION

This invention relates to a pop-up-package assembly of sheet materialand method of packaging a flat product such as a compact disc (“CD”)digital video disc (“DVD”) a credit card or the like into a closedpackage assembly having a thin lateral profile which opens to form athree dimensional stand for the product.

The pop-up-package of the present invention is designed such that theflat product can be incorporated into the package during assembly toform a closed package assembly possessing a thin lateral profile forplacement of the closed package assembly in a printed publication suchas a magazine which when opened forms a three dimensional pop-up-standfor display and removal of the flat product. The flat product is onlypartially embedded in the package assembly such that when the packageassembly is opened the product is readily removable from thepop-up-stand.

Other advantages of the invention will become apparent from thefollowing description when read in conjunction with the drawings ofwhich:

DESCRIPTION OF THE DRAWINGS

FIG. 1 and FIG. 1(a) represent, in combination, a schematic perspectiveview of a preferred method for forming the pop-up-package assembly ofthe present invention with FIG. 1(a) representing a continuation of FIG.1 with each of the Figures to be connected to one another as indicatedby the arrows;

FIGS. 2 a,2 b and 2 c are perspective views illustrating the foldingsequence for forming of the pop-up-package of the present invention;

FIGS. 3 a, 3 b, 3 c and 3 d are perspective views illustrating theassembled pop-up-package of the present invention in the opened positionwith the flat product illustrated using dotted lines; and

FIG. 4 is a perspective view showing the pop-up-package of the presentinvention for a CD or DVD in a partially closed position.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIG. 1 and FIG. 1 a which schematically illustrates apreferred method for assembling the pop-up-package assembly 10 of thepresent invention as shown in FIG. 4. A single continuous web ofpreferably paper 11 or any other conventional sheet material includingcardboard or even plastic having two major linear panels (horizontallyoriented columns), hereafter defined as major panel 1 and major panel 2,is shown in FIG. 1 for processing into a pop-up-package assembly 10 asis shown in FIG. 4. Major Panel 1 and major Panel 2 each containsub-panels, which are hereafter defined as sub-panels 1 a, 1 b, formajor Panel 1 and sub-panels 2 a, 2 b, 2 c, 2 d and 2 e for major Panel2. The sub-panels 1 a and 1 b are separated by a score or perforationline 12 and the sub-panels 2 a, 2 b, 2 c, 2 d and 2 e are separated fromone another by score or perforation lines 13 a, 13 b 13 c and 13 d. Thesingle continuous paper web 11 is fed from a paper web supply roll (notshown) by a conventional feed mechanism (not shown) past a conventionalfixed slitting device (not shown) so as to separate the major Panels 1and 2 along a press or slit line 14. Prior to slitting, an adhesive,preferably of the spline glue type, is applied to Major Panel 1 to formthree linear parallel lines of adhesive 15, 16 and 17 which respectivelyextend vertically down the panel. In the same manner similar adhesive isapplied on sub-panel 2 a of Major Panel 2 using e.g., a flexographic orequivalent technique to form an array of glue lines 18 which define ageometrical space in which the flat product, such as a CD, DVD, creditcard or other such substantially flat product may be placed to at leastpartially surround, or contain the flat product. It should be understoodthat the web of paper 11 may be printed upon in a conventional mannerbefore or during the assembly procedure. The printing operations do notform a part of the present invention and will not hereafter bediscussed.

Panel 2 is overlaid upon Panel 1 using e.g. a conventionalribbon-diverting tool such as a displacement bar assembly (not shown)such that Panel 2 is caused to overlay Panel 1. The overlaying of Panel2 onto Panel 1 is illustrated in FIG. 1 at the bottom portion thereof.It is important that Panel 2 overlay Panel 1 to achieve correctoverlaying of the perforations in a suitable manner such that the middleperforation line 13 b on Panel 2 directly overlays the line ofperforations 12 in Panel 1. Alternatively, the overlaying of perforationlines may be accomplished by employing a single deep perforation throughthe overlaid pair of major panels 1 and 2 thereby causing coincidencealong the appropriate center line on Panel 2 with the line ofperforations 12 on Panel 1. Once Panel 2 is folded over Panel 1, theadhesive lines 15, 16 and 17 previously applied to Panel 1 attach to theunderside of Panel 2 wherein a first line of adhesive is attached to theunderside of sub-panel 2 b, and both the second and third lines ofadhesive are attached to the underside of sub-panel 2 c. Following thisprocedure, sub-panels 2 d and 2 e are not directly adhered to Panel 1and may thereupon be caused to fold on their lines of perforations (orscore lines) by means of such conventional apparatus as a “plow folder.”

Subsequent to folding panel 2 e, the flat product such as a compact disc(CD) or other flat object is placed on panel 2 a, as is shown in FIG. 1a with the CD positioned to avoid contact both with the previouslyapplied adhesive and the interior edge of panel 2 a. It may be desirableto have a fugitive adhesive spot applied prior to placing the flatproduct in order to prevent its movement during the following foldingactions and web travel. Such fugitive adhesive does not affect therequired properties of CD's or credit cards. Alternatively oradditionally, a static charge is applied to the panel 2 a surface toprevent object movement.

Thereafter sub-panels 1 b and 2 c are folded over in combinationutilizing their superimposed perforations (or scores). The end result asshown in FIGS. 3 a-3 d and FIG. 4 is a closed package containing theflat product tucked in a pocket or flap 20 formed between sub-panel 2 band 2 d as shown in FIG. 3 a-3 d. It is noted that sub-panel 2 b remainsnon-adhered while sub-panel 2 a becomes adhered to what had been theunderside of the previously folded sub-panel 2 d.

It should further be noted that, if desired, a third major panel (notshown) may be used and placed adjacent to Panel 1, to constitute a widerstarting web than as described above to provide a secondary cover andadditional print area. In addition, a wider Panel 1 can serve to providea “tag” extension suitable for binding into a magazine, instructionmanual and similar bound publications. A line of perforations in such a“tag” parallel to the binding will permit removal of the pop-up packagefrom the binding.

1. A method of packaging flat products such as a computer disk into apackage assembly of sheet material which when closed possesses a thinlateral profile and when opened forms a three dimensional display standcomprising the steps of: providing a single continuous web of materialhaving two horizontally oriented columns defining first and second majorpanels having a vertical slit line separating the first major panel fromthe second major panel; forming sub-panels in the first major panel withat least one vertically extending score or perforation line centrallylocated for separating the sub-panels; forming sub-panels in the secondmajor panel with a plurality of parallel spaced vertically extendingscore or perforation lines for separating each of the sub-panels in thesecond major panel; applying an adhesive to each of the major panels toform linear parallel lines of adhesive on the first of major panelextending vertically down the first major panel and to form an array ofadhesive lines on the second major panel at a location adjacent to thevertical slit line separating the first major panel from the secondmajor panel; separating the first major panel from the second majorpanel along said vertical slit line; folding the second major panel overthe first major panel such that at least the two outer sub-panel in thesecond major panel furthest from the slit line overlies said centrallylocated score or perforation line in said first major panel withoutcausing any adherence between said of outer sub-panels and the firstmajor panel; folding over said two outer sub-panels over score orperforation lines to form a pocket or flap between an outer sub-paneland one of the other previously folded sub-panels for the placement of aflat product; folding the sub-panels of the first and second major panelinto a folded over assembly which remains in a three dimensionalconfiguration when the assembly is folded open and forms a substantiallytwo dimensional configuration when the assembly is folded closed; andcutting the web transversely to form a plurality of package assembliesone for each flat product.
 2. A method as defined in claim 1 wherein thesecond major panel is folded over the first major panel such that thecenter of said second major panel overlies said centrally located scoreor perforation line in said first major panel.
 3. A method as defined inclaim 1 wherein the second major panel is folded over the first majorpanel so as to cause substantial alignment of either the center of thesecond major panel with the centrally located score or perforation linein said first major panel or between one of said plurality of verticallyspaced score or perforation lines in said second major panel and thecentrally located score or perforation line in said first major panel.4. A method as defined in claim 2 wherein said array of adhesive lineson the second major panel lie in a horizontal direction and/or at acuteangles thereto.
 5. A method as defined in claim 2 further comprisingforming at least one fugitive adhesive spot in said pocket or flap inwhich the product is placed for preventing movement of the product.
 6. Amethod as defined in claim 2 further comprising adding a third majorpanel to the continuous web of material forming the first and secondmajor panels to constitute a wider starting web and to provide a tagextension suitable for binding the package into a bound publication suchas a magazine.
 7. A method as defined in claim 6 further comprisingadding a line of perforations in such tag extension parallel to thebinding to permit removal of the packaged assembly from the boundpublication.
 8. A pop-up-package assembly of sheet material for a flatproduct such as a computer disk for storing the flat product in thepackage assembly comprising a plurality of major panels each includingsub-panels and an array of lines of adhesive dispersed to permit thepanels when folded over to adhere for forming a substantially twodimensional closed configuration having a thin lateral profile and toopen into a self supporting configuration defining a three dimensionaldisplay stand for the stored product.
 9. A pop-up-package assembly ofsheet material as defined in claim 8 wherein the package assembly ofsheet material comprises: a first and second major panel each havingsub-panels with lines of perforations or score lines permitting each tobe folded over one another such that a pocket or flap is formed betweena first outer sub-panel of said second major panel and a sub-panel ofsaid first major panel for the placement of a flat product and whereinthe second major panel has at least another outer sub-panel whichoverlies the first outer sub-panel; and wherein the sub-panels of thefirst and second major panels are folded over so that the sheet materialforms a self supporting three dimensional configuration when folded openand when folded closed substantially form a two dimensionalconfiguration possessing a thin lateral profile.